January 2009

Inside this issue...

• News & Info ...p. 86

• The Reality of Crimp Force Monitoring – Part 1 ...p. 91

• Practical, Cost-Effective Ultrasonic Metal Welding Solutions ...p. 96

• Spotlight On Wire Processing Machines ...p. 94

• New Products ...p. 98

Presented by...www.wiretech.com

Focused News, Information and Products for Wire & Cable Processors, Distributors and End Users.

Wire & Cable Connector

Top Products of 2008 ...Page 88

Melissa Alleman,Sonobond Ultrasonics

www.SonobondUltrasonics.com

Practical, Cost-Effective

Ultrasonic Metal Welding Solutions

Metal welders made by Sonobond Ultrasonics, West Chester, PA, USA, continue to offer significant advan-tages over other brands of ultrasonic welding equip-ment. Sonobond units use the patented Wedge-Reed coupling system to combine high vibratory force with low amplitude ultrasonics. This results in the most reli-able, repeatably accurate welds in the industry.

We are pleased to be able to offer such a broad range of practical, cost-effective ultrasonic metal welding solutions. Our ultrasonic metal welders can be custom-ized to the specific needs of manufacturers. And we back Sonobond technology with superior customer service—before, during and after installation.

Single Pulse WeldingAn example of Sonobond’s state-of-the art technology is the SonoWeld® 1600 Digital Metal Spot Welder Se-ries. These units are designed to perform spot welds, wire-to-terminal and wire-to-wire welding—all in a single pulse. This microprocessor-controlled system is easy to use and can join multiple layers and/or delicate foils to tabs or terminals for lithium-ion and NiMH battery assembly. The SonoWeld 1600 features a digital display for selecting welding modes by time, total energy or final weld thickness. These units allow storage and recall of over 250 weld protocols. They are also available with outputs of 1500 or 2500 W of power for welding nonferrous similar or dissimilar metals including copper to aluminum.

Splicing Wire BundlesThe Sonobond SpliceRite™ Ultrasonic Wire Splicer makes the lowest, most reliable electrical connections possible. It provides a true solid-state metallurgical

January 200996 Wire & Cable Connector

bond, without melting wires or producing arcs, sparks or fumes. The SpliceRite is capable of bonding wire bundles—even when the wires are heavily oxidized. No other ultrasonic welder does so well. Manufactur-ers have found they can rely on this unit for high-qual-ity, high-strength wire connections, while eliminating any need to clip, solder, crimp or dip.

SonoWeld® 1600 Digital Metal Spot Welder performs spot welds, wire-to-terminal and wire-to-wire

welding—all in a single pulse.

The Sonobond SpliceRite™ Ultrasonic Wire Splicer makes the lowest, most reliable electrical

connections possible.

January 2009

January 2009 Wire & Cable Connector 97

Spot Welding of Nonferrous MetalsSonobond Ultrasonics’ Weldmaster™ Ultrasonic Metal Welder Series creates a true metallurgical bond for welding nonferrous materials for wire-to-termi-nal, wire-to-wire and thin sheet metal applications. The units can spot weld aluminum up to 0.040" thick and copper up to 0.032" thick. This spot welding is usually completed in less than 1.5 seconds, although time will vary according to the thickness and types of materials being joined.

One unit in Sonobond’s Weldmaster Series, the Model MH-2014D, features a rugged modular frame construc-tion for easy integration into automated assembly lines. It is equipped with pneumatically operated tooling for welding stranded and solid wire as used in automotive and appliance wire harnesses.

Effective Crimping & SealingThe hand-guided Sonobond Tube Terminator™ creates quick, airtight seals in one easy step, without consuma-bles or brazing. It takes only seconds to ultrasonically pinch off tubes and seal them. This is true even when the tubes are already charged with coolants, fluids or gases. As a result, production speeds are increased and defects reduced. In addition, many manufacturers have found the Tube Terminator—which weighs less than 30 lb—to be ideal for spot welding applications.

Advantages of Ultrasonic WeldingUltrasonic welding uses a welding tip to direct high-frequency ultrasonic energy to the surfaces of the met-als being bonded. The energy disperses the oxides and surface films between the workpieces. A true metal-lurgical bond is created without melting the materials. Ultrasonic welding offers many important advantages because it is environmentally friendly, produces no waste and is economical to use.

A Leader in Ultrasonic Welding TechnologySonobond is a worldwide leader in the application of ultrasonic welding and bonding technology. In 1960, Sonobond—then known as Aeroprojects—received the first patent ever awarded for ultrasonic metal welding. During the intervening 48 years, Sonobond has earned an outstanding reputation for its pioneer-ing work and quality-engineered products. Today, Sonobond manufactures a complete line of ultrasonic bonding and welding equipment for a wide variety of customers in the automotive, appliance, electrical, HVAC, aerospace, filtration, medical and apparel industries. Sonobond backs its technology with a com-mitment to superior customer service and a willing-ness to work closely with manufacturers to develop practical solutions to their specific ultrasonic welding and bonding needs.

Additional details about Sonobond products—as well as information about its free, no-obligation Ultrasonic Welding Viability Test—are available by visiting the company’s website below. www.SonobondUltrasonics.com

Weldmaster™ Ultrasonic Metal Welder Series creates a true metallurgical bond for welding nonferrous materials for wire-to-terminal, wire-to-wire and

thin sheet metal applications.

Sonobond Tube Terminator™ creates quick, airtight seals in one easy step, without consumables or brazing.